Producing method of light emitting diode device and light emitting diode element

ABSTRACT

A method for producing a light emitting diode device includes the steps of preparing a phosphor layer formed in a sheet state; forming a light semiconductor layer on one surface in a thickness direction of the phosphor layer; forming an electrode portion on one surface of the light semiconductor layer; forming an encapsulating resin layer containing a light reflecting component so as to cover the light semiconductor layer and the electrode portion; producing the light emitting diode element by partially removing the encapsulating resin layer so as to expose one surface of the electrode portion; and allowing the electrode portion to be electrically connected to the terminal, so that the light emitting diode element is flip-chip mounted on the base board.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority from Japanese Patent Applications No. 2011-081853 filed on Apr. 1, 2011 and No. 2011-069775 filed on Mar. 28, 2011, the contents of which are hereby incorporated by reference into this application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a producing method of a light emitting diode device and a light emitting diode element, to be specific, to a producing method of a light emitting diode device and a light emitting diode element used in the producing method.

2. Description of Related Art

In recent years, as a light emitting device that is capable of emitting high-energy light, a white light emitting device has been known. In the white light emitting device, for example, a base board, an LED (light emitting diode) laminated thereon, emitting blue light, a phosphor layer that can convert the blue light into yellow light and covers the LED, and an encapsulating layer that encapsulates the LED are provided. The white light emitting device emits high-energy white light by color mixing of the blue light emitted from the LED, which is encapsulated by the encapsulating layer and to which electric power is supplied from the base board, transmitting through the encapsulating layer and the phosphor layer, and the yellow light that is converted in wavelength from a part of the blue light in the phosphor layer.

As a method for producing the white light emitting device, for example, the following method has been proposed (ref: for example, Japanese Unexamined Patent Publication No.

The proposed method is as follows. That is, a base, which has a board portion and a white reflecting frame portion protruding from the circumference portion thereof toward the upper side, is first formed. Next, a semiconductor light emitting element is subjected to wire bonding in a bottom portion of a concave portion, which is formed at the center of the board portion by the reflecting frame portion, so as to be spaced apart from the inner side of the reflecting frame portion.

Next, a mixture of a phosphor and an epoxy resin in a liquid state is filled in the concave portion by application, subsequently the phosphor is spontaneously precipitated in the bottom portion of the concave portion, and then the epoxy resin is heat cured.

In the white light emitting device obtained by the method proposed in Japanese Unexamined Patent Publication No. 2005-191420, the phosphor layer (a wavelength conversion layer) that contains the phosphor formed by a precipitation at high concentrations is defined in a region at the upper side of the semiconductor light emitting element and an encapsulating portion that contains the epoxy resin at high concentrations is defined in a region at the upper side of the phosphor layer.

In the white light emitting device, the semiconductor light emitting element radially emits the blue light. Of the emitted blue light, a part thereof emitted from the semiconductor light emitting element toward the upper side is converted into the yellow light in the phosphor layer and the remaining light transmits through the phosphor layer. The blue light emitted from the semiconductor light emitting element toward the side is reflected at the reflecting frame portion and then toward the upper side. The white light emitting device in Japanese Unexamined Patent Publication No. 2005-191420 emits the white light by color mixing of the blue light and the yellow light.

SUMMARY OF THE INVENTION

However, the phosphor layer in Japanese Unexamined Patent Publication No. 2005-191420 is a region defined according to a difference in concentration of the phosphor that is produced by a spontaneous precipitation of the phosphor in the mixture, so that a thickness of the phosphor layer easily becomes non-uniform. In that case, there is a disadvantage that efficiency of the wavelength conversion in the phosphor layer becomes non-uniform and the white light emitting device emits uneven white light.

To form the phosphor layer, the above-described spontaneous precipitation is used, so that long hours are required. In addition, it is necessary to control the hours strictly, so that a production process becomes complicated. As a result, there is a disadvantage that production costs are increased.

In addition, there is also a disadvantage that a light semiconductor layer is spaced apart from the reflecting frame portion, so that a part of the light emitted from the light semiconductor layer toward the side is absorbed in the encapsulating portion before being reflected at the reflecting frame portion and therefore, extraction efficiency of the light is reduced.

Furthermore, in the white light emitting device in Japanese Unexamined Patent Publication No. 2005-191420, the phosphor layer and the encapsulating portion are sequentially formed on the semiconductor light emitting element, so that even when heat, which is produced when the semiconductor light emitting element emits light, is transmitted to the phosphor layer that contains the phosphor at high concentrations, the heat is thereafter easily stored by the encapsulating portion that contains the epoxy resin at high concentrations. Thus, there is a disadvantage that a heat dissipation of the semiconductor light emitting element at the time of the emission becomes insufficient and as a result, luminous efficiency of the semiconductor light emitting element is reduced.

In the white light emitting device in Japanese Unexamined Patent Publication No. 2005-191420, there is a disadvantage that the semiconductor light emitting element is connected to the board portion by the wire bonding, so that brightness is reduced due to a shadow of a wire.

It is an object of the present invention to provide a producing method of a light emitting diode device that is capable of suppressing an increase in production costs, and preventing a reduction in luminous efficiency of a light semiconductor layer and emitting uniform white light to improve extraction efficiency of light, and a light emitting diode element used in the producing method.

The method for producing a light emitting diode device of the present invention, provided with a base board including a terminal and a light emitting diode element flip mounted on the base board, includes the steps of preparing a phosphor layer formed in a sheet state; forming a light semiconductor layer on one surface in a thickness direction of the phosphor layer; forming an electrode portion on one surface in the thickness direction of the light semiconductor layer so as to be connected to the light semiconductor layer; forming an encapsulating resin layer containing a light reflecting component so as to cover the light semiconductor layer and the electrode portion; producing the light emitting diode element including the phosphor layer, the light semiconductor layer, and the electrode portion by partially removing the encapsulating resin layer so as to expose one surface in the thickness direction of the electrode portion; and allowing the light emitting diode element to be disposed in opposed relation to the base board in the thickness direction, and the electrode portion to be electrically connected to the terminal, so that the light emitting diode element is flip-chip mounted on the base board.

A light emitting diode element of the present invention includes a phosphor layer formed in a sheet state, a light semiconductor layer formed on one surface in the thickness direction of the phosphor layer, an electrode portion formed on one surface in the thickness direction of the light semiconductor layer so as to be connected to the light semiconductor layer, and an encapsulating resin layer that covers the light semiconductor layer and the electrode portion and exposes one surface in the thickness direction of the electrode portion, containing a light reflecting component.

In the method for producing the light emitting diode device of the present invention using the light emitting diode element of the present invention, the phosphor layer formed in a sheet state is prepared, so that the uniform phosphor layer can be reliably formed. Therefore, a uniform wavelength conversion can be achieved in the phosphor layer. As a result, the light emitting diode device obtained by the method for producing the light emitting diode device of the present invention can emit uniform white light.

In the method for producing the light emitting diode device of the present invention using the light emitting diode element of the present invention, the phosphor layer, which is formed in a sheet state, is prepared in advance, so that the phosphor layer can be easily formed in a short time. Therefore, an increase in the production costs can be suppressed.

In addition, in the method for producing the light emitting diode device of the present invention using the light emitting diode element of the present invention, the encapsulating resin layer that contains the light reflecting component is formed so as to cover the light semiconductor layer, so that light emitted from the light semiconductor layer is reflected by the light reflecting component of the sealing resin layer before being absorbed by another member. Therefore, the extraction efficiency of the light can be improved.

Furthermore, in the light emitting diode device obtained by the method for producing the light emitting diode device of the present invention using the light emitting diode element of the present invention, the phosphor layer is formed on the other surface in the thickness direction of the light semiconductor layer, so that heat of the light semiconductor layer can be dissipated toward the other side in the thickness direction via the phosphor layer. Therefore, a reduction in the luminous efficiency of the light semiconductor layer can be prevented.

In the method for producing the light emitting diode device of the present invention using the light emitting diode element of the present invention, the light emitting diode element is flip-chip mounted on the base board, so that the brightness can be improved and the extraction efficiency can be further improved.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a sectional view of one embodiment of a light emitting diode element of the present invention.

FIG. 2 shows process drawings for illustrating one embodiment of a method for producing a light emitting diode device of the present invention:

(a) illustrating a step of preparing a phosphor layer and

(b) illustrating a step of forming a light semiconductor layer.

FIG. 3 shows process drawings for illustrating one embodiment of a method for producing the light emitting diode device of the present invention, subsequent to FIG. 2:

(c) illustrating a step of forming an electrode portion and

(d) illustrating a step of forming an encapsulating resin layer.

FIG. 4 shows process drawings for illustrating one embodiment of a method for producing the light emitting diode device of the present invention, subsequent to FIG. 3:

(e) illustrating a step of partially removing the encapsulating resin layer and

(f) illustrating a step of allowing the encapsulating resin layer and the phosphor layer to be subjected to a cutting process.

FIG. 5 shows process drawings for illustrating one embodiment of a method for producing the light emitting diode device of the present invention, subsequent to FIG. 4:

(g) illustrating a step of allowing the light emitting diode element to be flip-chip mounted on the base board and

(h) illustrating a step of obtaining the light emitting diode device.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a sectional view of one embodiment of a light emitting diode element of the present invention.

In FIG. 1, a light emitting diode element 20 includes a phosphor layer 17, a light semiconductor layer 3 that is formed on the upper surface (one surface in a thickness direction) of the phosphor layer 17, an electrode portion 4 that is formed on the upper surface (one surface in the thickness direction) of the light semiconductor layer 3, and an encapsulating resin layer 14 that encapsulates the light semiconductor layer 3. The light emitting diode element 20 is produced in production processes in FIGS. 2 (a) to 4 (f) to be described later. Thereafter, as referred in the production process in FIG. 5 (g) to be described later, the light emitting diode element 20 is reversed upside down (turned over) to be flip mounted on a base board 16 (described later).

As shown in FIG. 1, the phosphor layer 17 is formed in a sheet state. To be specific, the phosphor layer 17 is formed so as to correspond to the outer shape of the light emitting diode element 20.

The phosphor layer 17 is formed of, for example, a phosphor composition that contains a phosphor.

Preferably, the phosphor composition contains the phosphor and a resin.

An example of the phosphor includes a yellow phosphor that is capable of converting blue light into yellow light. An example of the phosphor includes a phosphor obtained by doping a metal atom such as cerium (Ce) or europium (Eu) into a composite metal oxide, a metal sulfide, or the like.

To be specific, examples of the phosphor include garnet type phosphor having a garnet type crystal structure such as Y₃Al₅O₁₂:Ce (YAG (yttrium aluminum garnet):Ce), (Y, Gd)₃Al₅O₁₂:Ce, Tb₃Al₃O₁₂:Ce, Ca₃Sc₂Si₃O₁₂:Ce, and Lu₂CaMg₂(Si, Ge)₃O₁₂:Ce; silicate phosphor such as (Sr, Ba)₂SiO₄: Eu, Ca₃SiO₄Cl₂:Eu, Sr₃SiO₅:Eu, Li₂SrSiO₄: Eu, and Ca₃Si₂O₇:Eu; aluminate phosphor such as CaAl₁₂O₁₉:Mn and SrAl₂O₄:Eu; sulfide phosphor such as ZnS:Cu,Al, CaS:Eu, CaGa₂S₄:Eu, and SrGa₂S₄:Eu; oxynitride phosphor such as CaSi₂O₂N₂:Eu, SrSi₂O₂N₂:Eu, BaSi₂O₂N₂:Eu, and Ca-α-SiAlON; nitride phosphor such as CaAlSiN₃:Eu and CaSi₅N₈:Eu; and fluoride-based phosphor such as K₂SiF₆:Mn and K₂TiF₆:Mn. Preferably, garnet type phosphor is used, or more preferably, Y₃Al₅O₁₂:Ce (YAG) is used.

The above-described phosphor is, for example, in the form of a particle and the average particle size thereof is in the range of for example, 0.1 to 30 μm, or preferably 0.2 to 10 μm. The average particle size of the phosphor (a phosphor particle) is measured by a particle size distribution measurement device.

The phosphors can be used alone or in combination of two or more.

The mixing ratio of the phosphor is, for example, 1 to 50 mass %, or preferably 5 to 30 mass % with respect to the phosphor composition. The mixing ratio of the phosphor is, for example, 1 to 100 parts by mass, or preferably 5 to 40 parts by mass per 100 parts by mass of a resin.

The resin is a matrix in which the phosphor is dispersed, including, for example, transparent resins such as silicone resin, epoxy resin, and acrylic resin. Preferably, the silicone resin is used from the viewpoint of durability.

The silicone resin has, in its molecule, a main chain mainly composed of the siloxane bond (—Si—O—Si—) and a side chain, which is bonded to silicon atoms (Si) of the main chain, composed of an organic group such as an alkyl group (for example, a methyl group and the like) or an alkoxyl group (for example, a methoxy group).

To be specific, examples of the silicone resin include dehydration condensation type silicone resin, addition reaction type silicone resin, peroxide curable silicone resin, moisture curable silicone resin, and curable silicone resin. Preferably, the addition reaction type silicone resin is used.

The silicone resin has a kinetic viscosity at 25° C. in the range of, for example, 10 to 30 mm²/s.

The resins can be used alone or in combination of two or more.

The mixing ratio of the resin is, for example, 50 to 99 mass %, or preferably 70 to 95 mass % with respect to the phosphor composition.

The phosphor and the resin are blended at the above-described mixing ratio and are stirred and mixed, so that the phosphor composition is prepared.

The phosphor layer 17 has a thickness in the range of, for example, 20 to 500 μm, or preferably 50 to 300 μm.

The light semiconductor layer 3 is formed into a predetermined pattern at a central portion in a plane direction (a direction that is perpendicular to the thickness direction, that is, a right-left direction of the paper surface and a depth direction of the paper surface in FIG. 1) on the upper surface of the phosphor layer 17.

The light semiconductor layer 3 includes a buffer layer 6, an N-type semiconductor layer 7 that is formed thereon, a light emitting layer 8 that is formed thereon, and a P-type semiconductor layer 9 that is formed thereon.

The buffer layer 6 is formed so as to correspond to the outer shape of the light semiconductor layer 3.

The buffer layer 6 buffers a mismatch of a lattice constant of the N-type semiconductor layer 7 to be described next.

An example of a buffer material for forming the buffer layer 6 includes a semiconductor such as elemental semiconductor (single elemental semiconductor), oxide semiconductor, or compound semiconductor (except for the oxide semiconductor).

An example of the elemental semiconductor includes a Group 4B element (a Group 4B element in the long form of the periodic table, hereinafter the same) such as Si, Ge, and Sn.

Examples of the oxide semiconductor include an oxide of a typical element such as Al₂O₃, ZnO, and SnO₂, and an oxide of a transition element such as TiO₂, V₂O₅, Cr₂O₃, MnO₂, Fe₂O₃, NiO, and Cu₂O. These can be used alone or in combination.

The compound semiconductor is a compound in which a plurality of elements, except for O, are bonded. Examples thereof include a compound of a Group 3B element and a Group 5B element such as AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, InN, InP, InAs, InSb, AlGaN, InGaN, AlInN, and AlGaInN and a compound of a Group 2B element and a Group 6B element such as ZnS, SnSe, and ZnTe. Preferably, the compound of the Group 3B element and the Group 5B element is used.

Of the above-described semiconductors, preferably, the compound semiconductor is used.

The buffer layer 6 has a thickness in the range of, for example, 0.5 to 200 nm, or preferably 1 to 100 nm.

The N-type semiconductor layer 7 is formed on the entire upper surface of the buffer layer 6. An N-type semiconductor for forming the N-type semiconductor layer 7 is not particularly limited and a known N-type semiconductor is used. For example, an impurity semiconductor obtained by doping (adding) an impurity such as the Group 5B element or the Group 4B element into the above-described semiconductor in minute amounts is used.

The thickness of the N-type semiconductor layer 7 is not particularly limited and is in the range of, for example, 10 nm to 10 μm.

The light emitting layer 8 is, on the upper surface of the N-type semiconductor layer 7, formed into a predetermined pattern at one side end portion in the plane direction (the left side in FIG. 1). That is, the light emitting layer 8 exposes the upper surface of the N-type semiconductor layer 7 at the other side end portion in the plane direction (the right side in FIG. 1).

An example of a light emitting material for forming the light emitting layer 8 includes the same semiconductor as those illustrated in the buffer layer 6 described above. Preferably, the compound semiconductor is used.

The light emitting layer 8 has a thickness in the range of, for example, 20 to 300 nm, or preferably 30 to 200 nm.

The P-type semiconductor layer 9 is, on the entire upper surface of the light emitting layer 8, formed into the same pattern as that of the light emitting layer 8. A P-type semiconductor for forming the P-type semiconductor layer 9 is not particularly limited and a known P-type semiconductor is used. For example, an impurity semiconductor obtained by doping (adding) an impurity such as the Group 3B element or the Group 2A element into the above-described semiconductor in minute amounts is used. An example of the Group 2A element includes an alkaline earth metal such as Be and Mg.

The thickness of the P-type semiconductor layer 9 is not particularly limited and is in the range of, for example, 10 nm to 10 μm.

The electrode portion 4 is electrically connected to the light semiconductor layer 3 and includes an anode electrode 10 and a cathode electrode 11.

The anode electrode 10 is formed above the P-type semiconductor layer 9 so as to sandwich a transparent electrode 12 with the P-type semiconductor layer 9 and is electrically connected to the P-type semiconductor layer 9 via the transparent electrode 12.

The transparent electrode 12 is formed on the upper surface of the P-type semiconductor layer 9 and is disposed so as to be included in the P-type semiconductor layer 9 when projected in the thickness direction. An example of an electrode material for forming the transparent electrode 12 includes a metal oxide such as indium tin oxide (ITO), zinc oxide (ZnO), and tin oxide (SnO₂). The transparent electrode 12 has a thickness in the range of, for example, 10 to 300 nm, or preferably 20 to 200 nm.

The anode electrode 10 is formed into a pattern of being included in the transparent electrode 12 when projected in the thickness direction.

Examples of the electrode material for forming the anode electrode 10 include gold and aluminum. Preferably, gold is used. The anode electrode 10 has a thickness in the range of, for example, 10 to 300 nm, or preferably 20 to 200 nm.

The cathode electrode 11 is formed on the N-type semiconductor layer 7. To be specific, the cathode electrode 11 is formed on the upper surface of the N-type semiconductor layer 7 that is exposed from the P-type semiconductor layer 9 and the light emitting layer 8. The cathode electrode 11 is electrically connected to the N-type semiconductor layer 7.

Examples of the electrode material for forming the cathode electrode 11 include gold and aluminum. Preferably, gold is used. The cathode electrode 11 has a thickness in the range of, for example, 10 to 300 nm, or preferably 20 to 200 nm.

In the electrode portion 4, a bump 13 is provided.

The bump 13 is formed on the upper surface of the anode electrode 10 and that of the cathode electrode 11. Each of the bumps 13 is, in plane view, formed into a pattern of being included in the anode electrode 10 and the cathode electrode 11, respectively. The bump 13 is formed into substantially the same pattern as that of a terminal 15 (described later, FIG. 5 (g)) of the base board 16.

An example of a material for forming the bump 13 includes a conductor such as gold, silver, lead, tin, or alloys thereof (to be specific, solder and the like).

The thickness of each of the bumps 13 is adjusted so that before the light semiconductor layer 3 is flip-chip mounted on the base board 16, the upper surface of the bump 13 that is formed on the upper surface of the anode electrode 10 and that of the bump 13 that is formed on the upper surface of the cathode electrode 11 are the same in height. That is, the thickness of each of the bumps 13 is adjusted so that the upper surfaces of the bumps 13 are in the same position (the position in the thickness direction) when each of the bumps 13 is projected in the plane direction.

The encapsulating resin layer 14 contains a light reflecting component. To be specific, the encapsulating resin layer 14 is formed of an encapsulating resin composition that contains an encapsulating material and the light reflecting component.

An example of the encapsulating material includes a thermosetting resin such as thermosetting silicone resin, epoxy resin, thermosetting polyimide resin, phenol resin, urea resin, melamine resin, unsaturated polyester resin, diallyl phthalate resin, and thermosetting urethane resin. Preferably, the thermosetting silicone resin or the epoxy resin is used.

The light reflecting component is, for example, a white compound. To be specific, an example of the white compound includes a white pigment.

An example of the white pigment includes a white inorganic pigment. Examples of the white inorganic pigment include an oxide such as titanium oxide, zinc oxide, and zirconium oxide; a carbonate such as white lead (zinc carbonate) and calcium carbonate; and a clay mineral such as kaolin (kaolinite).

As the white inorganic pigment, preferably, the oxide is used or more preferably, the titanium oxide is used.

The titanium oxide can have characteristics such as a high degree of whiteness, a high light reflectivity, excellent hiding characteristics (hiding power), excellent coloring characteristics (coloring power), a high dispersibility, an excellent weather resistance, and a high chemical stability.

To be specific, the titanium oxide is TiO₂ (titanium oxide (IV), titanium dioxide).

A crystal structure of the titanium oxide is not particularly limited. For example, the crystal structure thereof is rutile, brookite (pyromelane), anatase (octahedrite), or the like. Preferably, the crystal structure thereof is rutile.

A crystal system of the titanium oxide is not particularly limited. For example, the crystal system thereof is a tetragonal system, an orthorhombic system, or the like. Preferably, the crystal system thereof is the tetragonal system.

When the crystal structure and the crystal system of the titanium oxide are rutile and the tetragonal system, respectively, it is possible to effectively prevent a reduction of the reflectance with respect to light (to be specific, visible light, among all, the light around the wavelength of 450 nm) even in a case where the encapsulating resin layer 14 is exposed to a high temperature for a long time.

The light reflecting component is in the form of a particle. The shape thereof is not limited and examples of the shape thereof include, for example, a sphere shape, a plate shape, and a needle shape. An average value of the maximum length (in a case of the sphere shape, the average particle size) of the light reflecting component is in the range of, for example, 1 to 1000 nm. The average value of the maximum length is measured by using a laser diffraction scattering particle size analyzer.

The mixing ratio of the light reflecting component per 100 parts by mass of the encapsulating material is, for example, 0.5 to 90 parts by mass, or preferably 1.5 to 70 parts by mass from the viewpoint of the coloring characteristics, the light reflectivity, and handling ability of the encapsulating resin composition.

The above-described light reflecting component is uniformly dispersed and mixed into the encapsulating material.

In addition, a filler can further be added into the encapsulating resin composition. That is, the filler can be used in combination with the light reflecting component (to be specific, the white pigment).

An example of the filler includes a known filler, except for the above-described white pigment. To be specific, an inorganic filler is used. Examples thereof include silica powder, talc powder, alumina powder, aluminum nitride powder, and silicon nitride powder.

Preferably, as the filler, the silica powder is used from the viewpoint of reducing a linear expansion coefficient of the encapsulating resin layer 14.

Examples of the silica powder include fused silica powder and crystalline silica powder. Preferably, the fused silica powder (that is, silica glass powder) is used.

Examples of the shape of the filler include, for example, a sphere shape, a plate shape, and a needle shape. Preferably, the sphere shape is used from the viewpoint of excellent filling characteristics and fluidity.

Therefore, preferably, the fused silica powder in a sphere shape is used as the silica powder.

The average value of the maximum length (in a case of the sphere shape, the average particle size) of the filler is in the range of, for example, 5 to 60 μm, or preferably 15 to 45 μm. The average value of the maximum length is measured by using the laser diffraction scattering particle size analyzer.

The addition ratio of the filler is adjusted so that the total amount of the filler and the light reflecting component per 100 parts by mass of the encapsulating resin is, for example, 10 to 80 parts by mass. And the addition ratio of the filler is adjusted so that the total amount of the filler and the light reflecting component per 100 parts by mass of the encapsulating resin is preferably 25 to 75 parts by mass, or more preferably 40 to 60 parts by mass from the view point of reducing the linear expansion coefficient and ensuring the fluidity.

The above-described encapsulating material, light reflecting component, and filler, which is added as required, are blended to be uniformly mixed, so that the encapsulating resin composition is prepared.

The encapsulating resin layer 14 is formed, on the phosphor layer 17, so as to cover the side surfaces of the light semiconductor layer 3 and the electrode portion 4 and to expose the upper surfaces (one surface in the thickness direction) of the electrode portion 4.

To be specific, the side surfaces of the bump 13 corresponding to the anode electrode 10, the upper surface exposed from the bump 13 and the side surfaces of the anode electrode 10, the upper surface exposed from the anode electrode 10 and the side surfaces of the transparent electrode 12, the upper surface exposed from the transparent electrode 12 and the side surfaces of the P-type semiconductor layer 9, the side surfaces of the light emitting layer 8, the side surfaces of the N-type semiconductor layer 7, and the side surfaces of the buffer layer 6 are covered by the encapsulating resin layer 14. The upper surface of the bump 13 corresponding to the anode electrode 10 is exposed from the encapsulating resin layer 14.

The side surfaces of the bump 13 corresponding to the cathode electrode 11, and the upper surface exposed from the bump 13 and the side surfaces of the cathode electrode 11 are covered by the encapsulating resin layer 14. The upper surface of the bump 13 corresponding to the cathode electrode 11 is exposed from the encapsulating resin layer 14.

In addition, the upper surface of the N-type semiconductor layer 7 (the upper surface of the N-type semiconductor layer 7 exposed from the light emitting layer 8 and the cathode electrode 11) is covered by the encapsulating resin layer 14.

Furthermore, the upper surface of the phosphor layer 17 exposed from the light semiconductor layer 3 is covered by the encapsulating resin layer 14.

In this way, the light semiconductor layer 3 is encapsulated by the encapsulating resin layer 14.

FIGS. 2 to 5 show process drawings for illustrating one embodiment of a method for producing a light emitting diode device of the present invention.

Next, a method for producing the light emitting diode device 21, by forming the above-described light emitting diode element 20 and subsequently, allowing the light emitting diode element 20 to be mounted on the base board 16, is described with reference to FIGS. 2 to 5.

In this method, as shown in FIG. 2 (a), the phosphor layer 17 that is formed in a sheet state is first prepared.

To prepare the phosphor layer 17, for example, the above-described phosphor composition is applied onto the top surface of a release substrate 18 shown in phantom lines to form a phosphor film (not shown) in a sheet state.

The release substrate 18 is formed in a sheet state and is formed of a resin material such as polyethylene terephthalate. The release substate 18 has a thickness in the range of, for example, 10 to 1000 μm.

Thereafter, the phosphor film is heated, for example, at 50 to 150° C. and is dried to be formed into a sheet state in the above-described pattern.

In this way, the phosphor layer 17 in a sheet state is prepared.

Next, in this method, as shown in FIG. 2 (b), the light semiconductor layer 3 is formed on the upper surface (one surface in the thickness direction) of the phosphor layer 17.

On the upper surface of the phosphor layer 17, a plurality of the light semiconductor layers 3 are formed at spaced intervals to each other in the plane direction.

To be specific, each of the light semiconductor layers 3 is laminated on the upper surface of the phosphor layer 17, for example, by a known growth method such as an epitaxial growth method. After performing the above-described growth method, each of the buffer layers 6, each of the N-type semiconductor layers 7, each of the light emitting layers 8, and each of the P-type semiconductor layers 9 are formed into the above-described pattern, for example, by an etching using a mask.

Next, in this method, as shown in FIG. 3 (c), the electrode portion 4 is formed on the upper surface (one surface in the thickness direction) of the light semiconductor layer 3 so as to be connected thereto by a known patterning method. A plurality of the electrode portions 4 are provided corresponding to the light semiconductor layers 3.

Next, in this method, as shown in FIG. 3 (d), the encapsulating resin layer 14 is formed on the phosphor layer 17 so as to cover a plurality of the light semiconductor layers 3 and a plurality of the electrode portions 4.

To form the encapsulating resin layer 14, the above-described encapsulating resin composition is applied onto the phosphor layer 17 including the light semiconductor layer 3 and the electrode portion 4, for example, by an application method using a laminator or an applicator to form an encapsulating film. Thereafter, when the encapsulating material is the thermosetting resin, the encapsulating film is cured by the heating.

When the encapsulating resin composition is formed into a sheet state in advance, the encapsulating resin layer 14 can also be formed by placing the encapsulating resin composition on the phosphor layer 17 so as to bury the light semiconductor layer 3 and the electrode portion 4 to be cured by the heating.

In addition, when the encapsulating resin composition contains the thermosetting resin in the form of a powder, the encapsulating resin layer 14 can also be formed by allowing the encapsulating resin composition to be heated and subjected to compression molding to be cured with a compression molding machine.

In this way, the encapsulating resin layer 14 is formed.

In the encapsulating resin layer 14 that is formed in this way, the upper surface thereof is formed in the upper side with respect to the upper surface of the electrode portion 4 (that is, the upper surface of the bump 13).

A length L between the upper surface of the encapsulating resin layer 14 and the upper surface of the bump 13 is in the range of, for example, 2000 μm or less, or preferably 10 to 1000 μm.

In this way, the light semiconductor layer 3 and the electrode portion 4 are encapsulated by the encapsulating resin layer 14.

Next, as shown in FIG. 4 (e), the encapsulating resin layer 14 is partially removed so as to expose the upper surface (one surface in the thickness direction) of the electrode portion 4.

To be specific, the upper side portion of the encapsulating resin layer 14 that is in the upper side with respect to the upper surface of the bump 13 is removed.

In the removal of the upper side portion of the encapsulating resin layer 14, for example, the above-described etching, machining (to be specific, grinding process and the like), or the like is used.

The encapsulating resin layer 14 in which the upper side portion is removed exposes the upper surface of the bump 13. In this way, in the encapsulating resin layer 14, the upper surface thereof around the bump 13 is formed to be flush with that of the bump 13.

In this way, a plurality of the light emitting diode elements 20 including the phosphor layer 17, each of the light semiconductor layers 3 that is encapsulated by the encapsulating resin layer 14, and each of the electrode portions 4 in which the side surfaces thereof are covered by the encapsulating resin layer 14 and the upper surface of the bump 13 is exposed from the encapsulating resin layer 14 are integrally formed.

Thereafter, as shown in dashed lines in FIG. 4 (f), the encapsulating resin layer 14 (and the release substrate 18) and the phosphor layer 17, which are located between the light emitting diode elements 20, are subjected to a cutting process (a dicing process).

That is, the phosphor layer 17 and the encapsulating resin layer 14 are subjected to the dicing process, so that the light emitting diode elements 20 are cut into plural pieces. That is, the light emitting diode elements 20 are individualized (singulated).

To be specific, the phosphor layer 17 and the encapsulating resin layer 14 around the light semiconductor layer 3 and the electrode portion 4 are subjected to the dicing process along the thickness direction shown in the dashed lines in FIG. 4 (f).

In this way, the light emitting diode element 20 shown in FIG. 1 can be obtained.

Thereafter, as shown in FIG. 5 (g), the obtained light emitting diode element 20 is reversed upside down (turned over) to be disposed in opposed relation to the base board 16 in the thickness direction.

The base board 16 is formed into a generally flat plate shape. To be specific, the base board 16 is formed of a laminated plate in which a conductive layer, as a circuit pattern, is laminated on an insulating board. The insulating board is formed of, for example, a silicon board, a ceramic board, a polyimide resin board, or the like. Preferably, the insulating board is formed of the ceramic board, to be specific, a sapphire (Al₂O₃) board. The conductive layer is formed of, for example, a conductor such as gold, copper, silver, or nickel. The conductors can be used alone or in combination.

The conductor layer includes the terminal 15.

The terminals 15 are formed at spaced intervals in the plane direction on the top surface of the insulating board and are formed into a pattern corresponding to the bump 13 described above. Although not shown, the terminal 15 is electrically connected to an electric power supply portion via the conductive layer.

Subsequently, as shown in FIG. 5 (h), the bump 13 is electrically connected to the terminal 15, so that the light emitting diode element 20 is flip-chip mounted on the base board 16.

In the flip-chip mounting, the light emitting diode element 20 is placed on the base board 16 so that the bump 13 and the terminal 15 are adjacent to each other in the thickness direction. Thereafter, the bump 13 is subjected to reflow, for example, by heating, ultrasonic wave, or the like. In this way, the bump 13 is allowed to be in contact with the terminal 15 in the thickness direction.

Thereafter, as shown by an arrow in the phantom lines in FIG. 5 (h), the release substrate 18 is peeled off from the phosphor layer 17.

In this way, the light emitting diode device 21 including the base board 16 and the light emitting diode element 20 that is flip mounted on the base board 16 can be obtained.

In the above-described method for producing the light emitting diode device 21 using the above-described light emitting diode element 20, the phosphor layer 17 that is formed in a sheet state is prepared, so that the uniform phosphor layer 17 can be reliably formed. Therefore, a uniform wavelength conversion can be achieved in the phosphor layer 17. As a result, the above-described light emitting diode device 21 can emit uniform white light.

In the above-described method for producing the light emitting diode device 21, the phosphor layer 17, which is formed in a sheet state, is prepared in advance, so that the phosphor layer 17 can be easily formed in a short time. Therefore, an increase in the production costs can be suppressed.

In addition, in the above-described method for producing the light emitting diode device 21, the encapsulating resin layer 14 that contains the light reflecting component is formed so as to cover the light semiconductor layer 3, so that light emitted from the light semiconductor layer 3 is reflected by the light reflecting component of the encapsulating resin layer 14 before being absorbed by another member. Therefore, the extraction efficiency of the light can be improved.

Furthermore, in the above-described light emitting diode device 21, the phosphor layer 17 is formed on the upper surface of the light semiconductor layer 3, so that heat of the light semiconductor layer 3 can be dissipated toward the upper side via the phosphor layer 17. Therefore, a reduction in the luminous efficiency of the light semiconductor layer 3 can be prevented.

In the above-described method for producing the light emitting diode device 21, the light emitting diode element 20 is flip-chip mounted on the base board 16, so that the brightness can be improved and the extraction efficiency can be further improved.

In the embodiment shown by the arrow in the phantom lines in FIG. 5 (h), the release substrate 18 is peeled off from the phosphor layer 17 after the light emitting diode element 20 is flip mounted on the base board 16. However, the timing of the peeling of the release substrate 18 is not limited to this. Alternatively, the release substrate 18 can also be peeled off from the phosphor layer 17 in the following timing: for example, as referred in FIG. 2 (a), after the preparation of the phosphor layer 17; as referred in FIG. 2 (b), after the formation of the light semiconductor layer 3; as referred in FIG. 3 (c), after the formation of the electrode portion 4; as referred in FIG. 3 (d), after the formation of the encapsulating resin layer 14; as referred in FIG. 4 (e), after the removal of the upper side portion of the encapsulating resin layer 14; or as referred in FIG. 4 (f), after the dicing process of the encapsulating resin layer 14 and the phosphor layer 17.

EXAMPLES

While the present invention will be described hereinafter in further detail with reference to Examples, the present invention is not limited to these Examples.

Example 1

A phosphor layer formed in a sheet state having a thickness of 75 μm was prepared (ref: FIG. 2 (a)).

That is, 26 parts by mass of phosphor particles composed of Y₃Al₅O₁₂:Ce (in a sphere shape, the average particle size of 8 μm) and 74 parts by mass of a silicone resin (addition reaction type silicone resin, kinetic viscosity (at 25° C.) of 20 mm²/s, manufactured by WACKER ASAHIKASEI SILICONE CO., LTD.) were blended and stirred uniformly, so that a phosphor composition was prepared.

Next, the prepared phosphor composition was applied onto the top surface of a release substrate made of polyethylene terephthalate having a thickness of 50 μm, so that a phosphor film in a sheet state was formed. Thereafter, the formed phosphor film was dried at 100° C., so that the phosphor layer in a sheet state having the above-described pattern was formed.

Next, a light semiconductor layer was formed on the upper surface of the phosphor layer (ref: FIG. 2 (b)).

That is, by an epitaxial growth method, a buffer layer made of GaN having a thickness of 30 nm, an N-type semiconductor layer made of N-type GaN (n-GaN:Si, hereinafter shown in the same manner) obtained by doping Si having a thickness of 5 μm, a light emitting layer made of InGaN having a thickness of 120 nm, and a P-type semiconductor layer made of p-GaN:Mg having a thickness of 50 nm were sequentially formed on the phosphor layer in the above-described pattern. The buffer layer and the N-type semiconductor layer were etched into the same pattern as described above by an etching after the formation of the N-type semiconductor layer. The light emitting layer and the P-type semiconductor layer were etched into the same pattern as described above by the etching after the formation of the P-type semiconductor layer.

Next, an electrode portion was formed on the upper surface of a light semiconductor layer so as to be connected thereto by a patterning method (ref: FIG. 3 (c)).

That is, a transparent electrode made of ITO having a thickness of 50 nm was formed on the P-type semiconductor layer and subsequently, an anode electrode made of gold having a thickness of 50 nm was formed on the transparent electrode. At the same time, a cathode electrode made of gold having a thickness of 50 nm was formed on the N-type semiconductor layer.

Subsequently, a bump made of gold was formed on the anode electrode and on the cathode electrode, respectively.

To be specific, the thickness of the bump on the anode electrode and that on the cathode electrode were adjusted so that the upper surfaces of the bumps were the same in height when the bumps were projected in the plane direction.

Next, an encapsulating resin layer was formed on the phosphor layer so as to cover the light semiconductor layer and the electrode portion (ref: FIG. 3 (d)).

To be specific, 100 parts by mass of thermosetting silicone resin, and 20 parts by mass of a particle of titanium oxide (TiO₂: tetragonal system of rutile) in a sphere shape having an average particle size of 300 nm were uniformly mixed, so that an encapsulating resin composition in a paste state was prepared. Subsequently, the prepared encapsulating resin composition was applied onto the phosphor layer including the light semiconductor layer and the electrode portion to form an encapsulating film in a semi-cured state (in a B-stage state). Thereafter, the encapsulating film was cured by heating.

In this way, the light semiconductor layer and the electrode portion were encapsulated by the encapsulating resin layer (ref: FIG. 4 (e)).

The upper surface of the encapsulating resin layer was formed in the upper side by 30 μm (L) with respect to the upper surface of the bump.

Thereafter, the upper side portion (the thickness of 30 μm) of the encapsulating resin layer was removed by a grinding process so as to expose the upper surface of the electrode portion (ref: FIG. 4 (f)). The upper side portion of the encapsulating resin layer was removed so that the upper surface of the electrode portion was flush with the upper surface of the encapsulating resin layer around the electrode portion.

In this way, a plurality of light emitting diode elements including the phosphor layer, each of the light semiconductor layers that was encapsulated by the encapsulating resin layer, and each of the electrode portions in which the side surfaces thereof were covered by the encapsulating resin layer and the upper surface of the bump was exposed from the encapsulating resin layer were integrally formed.

Thereafter, the phosphor layer and the encapsulating resin layer, which were located between the light emitting diode elements, were subjected to a dicing process, so that the light emitting diode elements were cut into plural pieces (ref: dashed lines in FIG. 4 (f)). That is, the light emitting diode elements were singulated.

Thereafter, the light emitting diode element was turned over. Subsequently, a base board in which a conductive layer including a terminal made of copper, nickel, and gold was laminated on the top surface of an insulating board made of sapphire (Al₂O₃), having a thickness of 1 mm was prepared, and the light emitting diode element was disposed in opposed relation to the base board (ref: FIG. 5 (g)).

Thereafter, the bump was subjected to reflow by heating and the bump was allowed to be in contact with a terminal, so that the bump was electrically connected to the terminal directly and the light emitting diode element was flip-chip mounted on the base board (ref: FIG. 5 (g)). Then, the release substrate was peeled off from the phosphor layer (ref: an arrow in the phantom lines in FIG. 5 (g)).

In this way, a light emitting diode device including the base board and the light emitting diode element mounted on the base board was produced.

While the illustrative embodiments of the present invention are provided in the above description, such is for illustrative purpose only and it is not to be construed as limiting the scope of the present invention. Modification and variation of the present invention that will be obvious to those skilled in the art is to be covered by the following claims. 

1. A method for producing a light emitting diode device, provided with a base board including a terminal and a light emitting diode element flip mounted on the base board, includes the steps of preparing a phosphor layer formed in a sheet state; forming a light semiconductor layer on one surface in a thickness direction of the phosphor layer; forming an electrode portion on one surface in the thickness direction of the light semiconductor layer so as to be connected to the light semiconductor layer; forming an encapsulating resin layer containing a light reflecting component so as to cover the light semiconductor layer and the electrode portion; producing the light emitting diode element including the phosphor layer, the light semiconductor layer, and the electrode portion by partially removing the encapsulating resin layer so as to expose one surface in the thickness direction of the electrode portion; and allowing the light emitting diode element to be disposed in opposed relation to the base board in the thickness direction, and the electrode portion to be electrically connected to the terminal, so that the light emitting diode element is flip-chip mounted on the base board.
 2. A light emitting diode element comprising: a phosphor layer formed in a sheet state, a light semiconductor layer formed on one surface in the thickness direction of the phosphor layer, an electrode portion formed on one surface in the thickness direction of the light semiconductor layer so as to be connected to the light semiconductor layer, and an encapsulating resin layer that covers the light semiconductor layer and the electrode portion and exposes one surface in the thickness direction of the electrode portion, containing a light reflecting component. 